P12007: Equilabrator System
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Foot Plate Design

Table of Contents

Foot Plate Weight Reduction Detailed Design Overview


The following information offers only a high level overview of the proposed designs, more details will be made available following the Detailed Design Review on 02/24/12

Selected Concept Review


Using a plate with the same Aluminum (6061-T6, density 0.0975lb/in^3) and dimensions (14.95" x 7.95" x 0.375") of the current product a portion of the underside of the foot plate will be removed through milling.


For details on why this concept was selected please view the Concept Selection page.


Relevant Engineering Specifications



Foot Plate Specifications

Foot Plate Specifications



For details on all required specifications please view the Engineering Specifications page.


Optimizing Weight Reduction Given Constraints


A series of models using different Milling patterns and thicknesses were ran using 'ANSYS' with the following results.

Proposed Footplate Designs (2/21/12)

Proposed Footplate Designs (2/21/12)



Milled Design #5, preferred design. (2/21/12)

Milled Design #5, preferred design. (2/21/12)



 Analysis Summary (2/21/12)

Analysis Summary (2/21/12)


Prioritized Design Risks and Mitigation Plans


* Prevented: Tested actual versus deflection versus the model, results are available on the Preliminary Test Plans page. (Test T-F-001)
*Prevented: Modeled stress on foot plate under 500lbs. Found that the created stress (35,000psi) was less than the max stress of material (40,000 psi).
* Prevented: Tested actual versus deflection versus the model, results are
* Prevented: Modeled deflection with a 500lb load, deflection was found less than absolute maximum of 0.07536in under 250lbs.

For a full list of identified project risks please view the Risk Assessment page.

Final Detailed Design Outputs


Click a link to download materials.



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